Process for producing sweet CO2 and hydrocarbon streams

Abstract

In a preferred embodiment, carbon dioxide and hydrogen sulfide are removed from a gaseous stream also containing a recoverable hydrocarbon product by CO₂ sweetening, bulk CO₂ removal, and hydrocarbon sweetening absorption steps, each absorption utilizing the same alkanolamine as absorbent. According to another aspect, each amine can be selected from the group consisting of tertiary amines and sterically hindered amines. According to yet another aspect, a feed gas comprising hydrogen sulfide and carbon dioxide can be introduced successively into a carbon dioxide sweetening absorption zone, then into a bulk CO₂ removal absorption zone, then into a hydrocarbon sweetening absorption zone. Alternatively, a feed gas comprising hydrogen sulfide and carbon dioxide can be introduced first into a bulk CO₂ removal absorption zone and then streams from the bulk CO₂ removal zone can be provided respectively to the hydrocarbon sweetening absorption zone and the CO₂ sweetening absorption zone.

Description

FIELD OF THE INVENTION

The invention relates to gas processing. In a particular aspect, the invention relates to processing gaseous streams comprising hydrocarbons, carbon dioxide (CO₂) and hydrogen sulfide (H₂ S) and producing sweet CO₂ and hydrocarbon product streams.

BACKGROUND OF THE INVENTION

Naturally occurring low quality sour gas reservoirs exist which contain, in addition to methane and other hydrocarbons, significant quantities of carbon dioxide and hydrogen sulfide. Such reservoirs have sometimes not been produced because of the expense of recovering hydrocarbon and other stream(s) meeting sales specifications and environmental requirements. Developments in recent years include carbon dioxide miscible flooding to facilitate enhanced oil recovery from certain reservoirs. Such carbon dioxide miscible flooding requires sources of large quantities of carbon dioxide, and if the carbon dioxide is to be transported over significant distances, the carbon dioxide should be substantially free of hydrogen sulfide to meet environmental regulations. Accordingly, efficient and economical processes for producing sweet high purity carbon dioxide and hydrocarbon streams meeting sales specifications and environmental requirements from such naturally occurring low quality sour natural gas reservoirs are highly desirable.

In addition, during the production of a reservoir by carbon dioxide miscible flooding it is known that after a time carbon dioxide breakthrough occurs, i.e., carbon dioxide appears in the produced fluids in significant quantities. Gaseous streams derived, for example, from wellhead separator(s) of such carbon dioxide miscible flood produced reservoirs can, therefore, have compositions similar to gas produced from naturally occurring low quality reservoirs, for example, high levels of carbon dioxide and significant amounts of hydrogen sulfide and hydrocarbons.

Typically, processing the above gases can involve sulfur recovery, usually by the Claus reaction. When the acid gas feed stream to the sulfur recovery facility contains 10 to 15 mol percent H₂ S or greater, the sulfur recovery can be carried out using Claus technology involving a furnace and/or one or more Claus reactors. For example, for acid gas feeds containing 40 to 50 mol percent H₂ S or greater, a straight through design Claus plant can be utilized; and, for feeds containing 40 to 50 mol percent H₂ S down to about 10 to 15 mol percent H₂ S, a split flow design Claus plant can be utilized. When the gaseous feeds are leaner in H₂ S, however, specialized designs must be utilized. Accordingly it is desirable in design of gas processing facilities to provide a Claus plant feed having greater than 10 to 15 mol percent H₂ S, thereby avoiding the use of the less efficient specialized designs.

Consequently, there is a continuing need for processes for treating gaseous streams containing significant quantities of CO₂ and H₂ S, in addition to hydrocarbons, which can economically produce sweet CO₂ and hydrocarbon product streams and concentrate H₂ S for feed to a sulfur recovery plant.

SUMMARY OF THE INVENTION

According to the invention, there is provided a process for removing hydrogen sulfide and carbon dioxide from a gaseous feedstream which also comprises hydrocarbons and for producing a sweet CO₂ stream, a sweet sales-quality hydrocarbon product stream, and an acid gas stream enriched in H₂ S suitable as feed for a sulfur recovery facility.

According to one embodiment of the invention, the gaseous feed stream can be introduced into a CO₂ sweetening absorption zone and contacted with a first aqueous alkanolamine solution stream under conditions effective for selectively removing hydrogen sulfide relative to carbon dioxide and for absorbing at least a major portion of the hydrogen sulfide from the gaseous stream, producing a first gaseous product stream and a first rich amine stream containing selectively absorbed hydrogen sulfide. The first gaseous product stream can then be introduced into a bulk CO₂ removal absorption zone and contacted with a second aqueous alkanolamine solution stream under conditions effective for absorbing and removing a major portion of carbon dioxide therefrom, producing a second gaseous product stream and a second rich amine stream containing the thus absorbed carbon dioxide. The second gaseous product stream can then be introduced into a hydrocarbon sweetening absorption zone and contacted with a third aqueous alkanolamine solution stream under conditions effective for selective removal of substantially all remaining hydrogen sulfide, and sufficient carbon dioxide to meet sales specifications, producing a third sweet gaseous product stream and a third rich amine stream.

In a further aspect of this embodiment of the invention, each of the first aqueous alkanolamine solution stream and the third aqueous alkanolamine solution stream comprises a substantially identical tertiary or a sterically hindered amine effective for selective H₂ S removal such as, for example, methyldiethanolamine (MDEA) or diisopropanolamine (DIPA), solution.

In yet a further aspect of this embodiment of the invention, the first rich amine stream and the third rich amine stream can be introduced into a first regeneration zone and absorbed carbon dioxide and hydrogen sulfide removed therefrom, producing the first lean aqueous alkanolamine solution stream and the third lean aqueous alkanolamine solution stream. The second rich amine stream can be introduced into a second regeneration zone and absorbed acid gases removed therefrom producing a CO₂ product stream lean in hydrogen sulfide and the second lean (or semilean) aqueous alkanolamine stream.

In yet a further aspect of this embodiment of the invention, each of the first, the second, and the third aqueous alkanolamine streams comprises a substantially identical tertiary or sterically hindered amine solution.

According to a second embodiment of the invention, the gaseous feedstream can be introduced into a bulk CO₂ removal absorption zone and contacted therein with a first aqueous alkanolamine solution stream under conditions effective for absorbing and removing a major portion of carbon dioxide, and at least a first portion of hydrogen sulfide from the gaseous stream, producing a first gaseous product stream and a first rich amine stream containing absorbed carbon dioxide and hydrogen sulfide. The first gaseous product stream can then be introduced into a hydrocarbon sweetening absorption zone and contacted therein with a second aqueous alkanolamine solution stream under conditions effective for removal of a major portion of the remaining hydrogen sulfide, producing a second (sweet) gaseous product stream comprising hydrocarbons and a second rich amine stream. Carbon dioxide and hydrogen sulfide absorbed in the first rich amine stream and the second rich amine stream can be removed by regeneration, producing an acid gas stream containing such removed carbon dioxide and hydrogen sulfide. The acid gas stream can then be introduced into a CO₂ sweetening absorption zone and contacted therein with a third aqueous alkanolamine solution stream under conditions selective for the removal of hydrogen sulfide relative to carbon dioxide, producing a second gaseous product stream comprising predominantly sweet carbon dioxide and a third rich amine stream containing absorbed hydrogen sulfide.

According to a further aspect of this embodiment of the invention, the first aqueous alkanolamine solution, the second aqueous alkanolamine solution, and the third aqueous alkanolamine solution, each comprises an alkanolamine selected from the group consisting of tertiary amines and sterically hindered amines effective for selective removal of hydrogen sulfide relative to carbon dioxide such as, for example, methyldiethanolamine.

According to the further aspect of this embodiment of the invention, the first rich amine stream can be introduced into a first regeneration zone and carbon dioxide and hydrogen sulfide removed therefrom, producing a first acid gas stream, and a first semilean alkanolamine solution stream which can be returned to the bulk CO₂ removal absorption zone. A portion of the first semilean alkanolamine solution stream can then be introduced into a second regeneration zone and a substantial portion of the remaining absorbed acid gas can be removed therefrom to produce a second acid gas stream and the second lean aqueous alkanolamine solution stream which can be returned to the hydrocarbon sweetening and the CO₂ sweetening absorption zones. The first acid gas stream can then be provided to the CO₂ sweetening absorption zone. The second acid gas stream can be provided directly to a Claus sulfur recovery unit or provided to a Pre-Claus selective H₂ S removal zone.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be further understood and appreciated from the following detailed description and the drawings in which:

FIG. 1 represents a block diagram of a first embodiment of the invention;

FIG. 2 represents a block diagram of a second embodiment of the invention;

FIG. 3 illustrates schematically the first embodiment of the invention; and

FIG. 4 illustrates schematically the second embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

According to the invented process, H₂ S and CO₂ can be removed by absorption from gaseous streams comprising H₂ S, CO₂, and hydrocarbons such as methane, ethane, and the like. The gaseous stream can be, for example, CO₂ miscible flood produced gas, or naturally occurring low quality sour natural gas, and comparable streams, and can contain broadly from about 10 to about 90 mol% CO₂, and from about 0.1 to about 20 mol% H₂ S.

According to a first embodiment of the invention, removal of H₂ S and CO₂ from the gaseous feed stream can proceed according to the invention in the following sequence of absorption steps: (1) CO₂ sweetening, (2) bulk CO₂ removal, and (3) hydrocarbon sweetening. A sweet CO₂ stream is produced in accordance with this embodiment of the invention by regenerating laden alkanolamine solution from Step (2) and an acid gas stream can be produced by regenerating laden alkanolamine solutions from Step (1) and Step (3).

Thus, referring to FIG. 1, a gaseous feedstream comprising H₂ S, CO₂, and hydrocarbons can be introduced by Line D into CO₂ Sweetening Zone A. An acid gas stream comprising H₂ S and CO₂ can be removed by Line E, for example, to a Claus Plant (not shown) for the recovery of sulfur. A gaseous product stream comprising hydrocarbons, CO₂, and less than a predetermined allowable amount of H₂ S, for example, less than 100 ppm H₂ S in the CO₂, can be removed from Zone A by Line F and introduced into Bulk CO₂ Removal Zone B. A major portion of the CO₂ in Line F is removed from the hydrocarbons in Zone B and can be removed as a sweet CO₂ stream in Line H, containing less than a predetermined allowable amount of H₂ S, for example, less than about 100 ppm H₂ S. A hydrocarbon stream greatly reduced in CO₂ content can be removed from Zone B by Line G and introduced into Hydrocarbon Sweetening Zone C. In Hydrocarbon Sweetening Zone C, further removal of CO₂ and H₂ S to below predetermined allowable limits, for example, to below 2 mol percent CO₂ and to below 4 ppm H₂ S, can occur producing, for example, a sales quality hydrocarbon residue gas product stream which can be removed by Line J. The rich amine stream from Zone C partly laden with H₂ S and CO₂ can, if desired, be returned to the Bulk CO₂ Removal Zone for further absorption of CO₂ as indicated by dashed line I.

According to a second embodiment of the invention, removal of H₂ S and CO₂ from the gaseous feed stream can proceed according to the following sequence of absorption steps: (1) bulk CO₂ removal (2) hydrocarbon sweetening of the gaseous product from step (1), and (3) sweetening of the sour CO₂ stream produced by regeneration of laden alkanolamine solution streams from Steps (1) and (2).

Thus, referring to FIG. 2, a gaseous feedstream comprising H₂ S, CO₂, and hydrocarbons can be introduced by Line DD into Bulk CO₂ Removal Zone M. A major portion of the CO₂, as well as of the H₂ S, is separated from the hydrocarbons in Zone M and can be removed as a sour CO₂ stream in Line Q to CO₂ Sweetening Zone O discussed below. A hydrocarbon stream greatly reduced in CO₂ content can be removed from Zone M by Line P and introduced into Hydrocarbon Sweetening Zone N. In Zone N, further removal of CO₂ and H₂ S to below predetermined allowable limits, for example, to below 2 mol percent CO₂ and below 4 ppm H₂ S can occur producing, for example, a sales quality hydrocarbon sweet residue gas product stream which can be removed by Line S. A rich amine stream partly laden with H₂ S and CO₂ can, if desired, be returned to the Bulk CO₂ Removal Zone M for further absorption of acid gases, as indicated by dashed line R. In CO₂ Sweetening Zone O, a sweet CO₂ stream having less than a predetermined allowable amount of H₂ S can be produced and removed by Line U. An acid gas stream comprising H₂ S and CO₂ can be removed by Line T.

In addition, it will be appreciated that further stages of selective H₂ S removal can, if desired, be utilized for further treatment of the acid gas stream to produce an acid gas feed enriched in H₂ S suitable as feed to a sulfur recovery facility. The invented process when applied, for example, to CO₂ miscible flood produced gases or to low quality sour natural gas, can be used to produce a residue (hydrocarbon) gas meeting pipeline specifications for H₂ S and CO₂, typically less than about 4 ppm H₂ S and less than about 2 mol% CO₂, a sweet CO₂ product gas containing less than, for example, about 100 ppm H₂ S, and, according to a preferred embodiment, an acid gas stream suitable as feed to a Claus plant containing not less than about 10 to 15 mol% H₂ S.

According to a preferred aspect of the invention, the same aqueous alkanolamine solution is utilized in the bulk CO₂ removal zone, the hydrocarbon sweetening zone, and the CO₂ sweetening zone, and comprises a single amine or a single amine mixture of amines selected from the group consisting of tertiary amines such as triethanolamine (TEA), methyldiethanolamine (MDEA) and the like, and sterically hindered amines effective for selective removal of H₂ S relative to carbon dioxide, such as, for example, DIPA. By using a single alkanolamine or a single mixture of alkanolamines, operation of the invented process is simplified as compared with alternative processes, for example, the alkanolamine regeneration facilities can be consolidated, and cross contamination of alkanolamine streams is virtually eliminated.

The alkanolamine solution according to the invention can have a concentration of amine about 1 to 7 moles per liter of the total solution, and preferably from about 2 to 5 moles per liter, depending primarily on the specific amine employed.

The alkanolamine solution according to the invention can include a variety of additives typically employed in amine solution gas removal processes, e.g., antifoaming agents, antioxidants, corrosion inhibitors, and the like. The amount of these additives will typically be in the range that they are effective, i.e., an effective amount. Also, the amines described herein may be admixed with other amines as a blend.

In the CO₂ sweetening absorption zone of the invention, the gaseous feed stream or the sour CO₂ gas stream can be contacted with an alkanolamine solution according to the invention and at least a major portion of the H₂ S can be removed from the gaseous stream producing a gaseous product stream and a rich amine stream. Preferably, the CO₂ sweetening absorption zone is operated to reduce the H₂ S content to, for example, less than about 100 ppm in the CO₂ contained in the gaseous product stream while minimizing the CO₂ content of the acid gas removed, that is, achieving maximum CO₂ "slippage" through the CO₂ sweetening absorber.

Selective absorption of H₂ S in the CO₂ sweetening zone can be promoted by limited contact time, low temperature, and special mechanical tray design features.

The high selectivity of tertiary amines for H₂ S as compared with CO₂ is believed to arise because these amines lack labile hydrogen atoms and, hence, cannot react directly with CO₂ to form carbamate structures such as shown in (I) below: ##STR1##

Similarly, in DIPA which can be used according to the invention, the reaction with CO₂ to form stable carbamate structures is sterically hindered. Consequently, sterically hindered amines such as DIPA and tertiary amines must absorb CO₂ by the relatively slow acid-base reaction sequence such as shown in (II) below which is far slower than the carbamate mechanism (I):

CO₂ +H₂ O⇄H₂ CO₃

H₂ CO₃ ⇄H+ +HCO₃-

HCO₃- ⇄H+ +CO₃-

H+ +[Amine]⇄[Amine]+ (II)

H₂ S, on the other hand, reacts directly with tertiary and sterically hindered amines by very rapid proton transfer such as shown in (III) below:

H₂ S+[Amine]⇄[Amine]+ +HS- (III)

Thus, by selecting vapor liquid contact times so as to load the amine solution with H₂ S but not so long as to allow significant CO₂ absorption to occur, a high degree of selectivity for H₂ S can be attained. The CO₂ sweetening absorption step according to the invention will generally involve contacting the normally gaseous stream with the alkanolamine solutions in any suitable contacting vessel. In such processes, the normally gaseous mixture containing H₂ S and CO₂ from which the H₂ S is to be selectively removed may be brought into intimate contact with the absorption solution using conventional means, such as a tower or vessel containing suitable packing (e.g., rings or saddles), trays (e.g., sieve plates), or other suitable vapor liquid contact devices. Further, in the selective H₂ S absorption steps of the invention, special vapor-liquid contacting devices such as are known in the art can be used to enhance H₂ S selectivity.

According to the invention, the CO₂ sweetening absorption step can be conducted by feeding the normally gaseous mixture into the lower portion of the CO₂ sweetening absorber while lean alkanolamine solution is fed into the upper region of the absorber. A gaseous product stream freed largely from the H₂ S, emerges from the upper portion of the tower, and a rich alkanolamine solution which contains the selectively absorbed H₂ S as well as some CO₂, leaves the tower near or at its bottom. Preferably, the inlet temperature of the alkanolamine solution during the absorption step is in the range of about 35° to about 60°C, and more preferably from about 40° to about 50°C Pressures may vary widely; acceptable pressures are between 20 to 1000 psia, and preferably between 25 to 250 psia in the absorber. The contacting takes place under conditions such that the H₂ S is selectively absorbed by the solution. The absorption apparatus is designed so as to limit the residence time of the liquid in the absorber to minimize CO₂ pickup while at the same time maintaining sufficient contact of gas with liquid to absorb a maximum amount of H₂ S. The amount of liquid required to be circulated to obtain a given degree of H₂ S removal will depend on the type and concentration of the amine and on the partial pressures of H₂ S and CO₂ in the feed gas.

A typical procedure for the CO₂ sweetening step of the process comprises selectively absorbing H₂ S via countercurrent contact of the gaseous mixture containing H₂ S and CO₂ with the aqueous alkanolamine solution in a column containing a plurality of trays at a moderate temperature, e.g., below 50°C, said tray column having fewer than 20 contacting trays, with e.g., 10 to 16 trays being typically employed.

After contacting the gaseous stream with the alkanolamine solution, which becomes saturated or partially saturated with H₂ S, the rich alkanolamine solution is regenerated so that it may be recycled back to the CO₂ sweetening absorber. Regeneration or desorption of the acid gases from the rich alkanolamine solution can be accomplished by conventional means such as pressure reduction of the solution and increase of temperature. Preferably, the solution is sent to a vessel of similar construction to that used in the absorption step, at the upper portion of the vessel, and passing an inert stripping gas, preferably steam, upwardly through the vessel. The regenerated lean alkanolamine solution, after having at least a portion of the H₂ S removed therefrom can be recycled back to the absorbing vessel. Makeup absorbent may be added as needed.

In a preferred regeneration technique, the H₂ S-rich amine solution from the CO₂ sweetening absorber can be sent to a regenerator wherein the absorbed H₂ S is stripped by steam which is generated by reboiling the solution. Preferably, the same regenerator can be used for regenerating the rich alkanolamine solutions from both the CO₂ sweetening absorber and the hydrocarbon sweetening absorber described in more detail below. Alternatively, of course, separate regenerators can be used. Pressure in the regenerator can be usually in the range of about 15 to 50 psia, preferably 20 to 30 psia. Stripper temperatures will, of course, depend on stripper pressure and amine concentration. The temperature can be typically in the range from about 100° to 130°C, preferably about 115° to 120°C Heating of the solution to be regenerated may suitably be effected by means of indirect heating with steam. It is also possible, however, to use direct injection of steam.

In the bulk CO₂ removal zone of the invention, a gaseous stream containing major amounts of CO₂ can be processed. Bulk CO₂ removal can be conducted by feeding the gaseous stream into the lower portion of the bulk CO₂ removal absorber while fresh lean alkanolamine solution, or as hereinafter described, preferably semilean alkanolamine solution, can be fed to the upper region of the bulk CO₂ absorber. A gaseous product stream, largely freed of CO₂, can thus be produced from the upper region of the absorber and a second rich alkanolamine solution, which contains absorbed CO₂, and H₂ S, can be removed from the tower near or at its bottom. The contacting takes place under conditions favoring removal of most of the CO₂ (for example, to less than about 5 to 10 mol% CO₂), i.e., high contact time and moderately high temperatures and pressures. Longer contact time favors CO₂ absorption as discussed above. As solution circulation rate decreases, pumping energy requirements decrease while net volumetric acid gas loading increases. Net volumetric acid gas loading is the volume of acid gas in the rich amine per unit volume of amine, minus the volume of acid gas in the lean amine per unit volume of amine. Reboiler energy requirements are directly dependent on the solution circulation rate and the regeneration temperature. Therefore, total energy consumption, which includes pumping and reboiler energy, is approximately minimized by maximizing the net volumetric acid gas loading of the alkanolamine. Thus, absorption and regeneration temperatures in the bulk CO₂ absorber are preferably set such that the volumetric acid gas loading is maximized. Mass transfer efficiency declines in both absorber and regenerator as temperature is reduced. Therefore, the optimum operating absorber and regenerator temperatures are generally somewhat higher than the theoretical optimum temperatures due to mass transfer efficiency limitations. In the preferred embodiment, the inlet temperature of the absorption solution during bulk CO₂ removal is approximately equal to the temperature in the bulk CO₂ absorber, and is in the range of about 60° to about 95° C., and more preferably from about 80° to about 90°C Absorber pressures may vary widely; acceptable pressures are between 100 to 1000 psia, and most preferably with CO₂ partial pressures of 150 to 300 psia in feed to the bulk CO₂ removal absorber.

A typical procedure for the bulk CO₂ removal absorption step of the process comprises absorbing CO₂, and H₂ S, via countercurrent contacting of a gaseous stream containing major amounts of CO₂ with an aqueous alkanolamine solution in an absorber having a plurality of trays at a temperature, in the range described above, said absorber having 15 to 30 trays, with, for example, 20 trays being typically used.

After contacting the gaseous stream, a rich alkanolamine solution stream is produced which is saturated or partially saturated with CO₂. The rich amine stream can be thoroughly regenerated with high energy consumption, for example, as described above in general terms for the CO₂ sweetening step, and recycled back to the bulk CO₂ removal absorber. Preferably, however, the regeneration can be accomplished with low energy consumption by an adiabatic, essentially atmospheric, flash regeneration procedure to yield a semilean alkanolamine solution which can be returned to the bulk CO₂ removal absorber. Various techniques can be advantageously used to increase efficiency, for example, a portion of the semilean alkanolamine solution withdrawn from the flash vessel can be fed to the lower region of the bulk CO₂ removal absorber without cooling while the remaining semilean alkanolamine solution can be cooled before being returned to the upper portion of the bulk CO₂ removal absorber. Such cooling of the solution can reduce the CO₂ partial pressure in the semilean solution and thereby can reduce the CO₂ content of the gaseous overhead product stream produced from the bulk CO₂ removal absorber. The cooled amine also cools the gaseous product stream before it enters the final hydrocarbon sweetening absorption zone where lower temperature favors H₂ S removal to a low level.

In the hydrocarbon sweetening zone of the invention, a gaseous stream from which major amounts of CO₂ and H₂ S have been removed, can be processed. The gaseous stream can be contacted with a well-stripped alkanolamine solution at lower temperature, 40°-50°C A gaseous product stream comprising residue gas having less than, for example, about 4 ppm H₂ S with slippage of CO₂ allowed up to about 2 mol% CO₂ consistent with sales gas specifications can thus be produced as well as a third rich alkanolamine solution comprising absorbed H₂ S and CO₂.

Regeneration of the rich alkanolamine solution from the hydrocarbon sweetening absorber can be as described above for regeneration of the rich alkanolamine solution from the CO₂ sweetening absorption zone. According to a preferred embodiment, the rich alkanolamine solutions from the CO₂ sweetening absorber and from the final hydrocarbon sweetening absorber can be combined and regenerated in the same regeneration zone producing a single acid gas stream and a single lean alkanolamine stream. Alternatively, separate regenerators for the CO₂ sweetening and final hydrocarbon sweetening absorbers can be used. The lean amine circulation to the hydrocarbon sweetening absorber will typically be only about 1-10% of the total amine circulation since only a small portion of H₂ S and CO₂ remains in the feed to the final hydrocarbon sweetening absorber. The regenerated alkanolamine solution can pass through a lean-rich exchanger and can be further cooled before entering the final hydrocarbon sweetening absorber. This absorber is designed to ensure H₂ S and CO₂ removal consistent with specifications on the product gas. Moreover, H₂ S removal to meet the tight sales gas specification is enhanced in the final hydrocarbon sweetening absorber following the bulk CO₂ removal because of (1) reduced total solution loading and (2) increased fraction of the total loading is due to H₂ S.

According to a preferred aspect of the invention, the bulk CO₂ removal absorber and the final hydrocarbon sweetening absorber can be combined in a single column. In this combination, the second gaseous product stream can be passed by a vapor path directly from the top of the bulk CO₂ removal absorber into the bottom region of the final hydrocarbon sweetening absorber. Separate columns can, of course, also be used. When a combined column is used, the rich amine from the final hydrocarbon sweetening absorber can be removed, for example, from a trapout tray just above the bulk CO₂ removal absorber. Alternatively, since the same alkanolamine solution is being utilized for both the hydrocarbon sweetening and bulk CO₂ removal zones, the rich amine stream from the final hydrocarbon sweetening absorber can be allowed to flow through the bulk CO₂ removal absorber to be further loaded with CO₂ before being withdrawn in admixture with the rich amine stream from the bulk CO₂ removal absorber.

As indicated above, during regeneration of the rich alkanolamine stream from the CO₂ sweetening absorption zone, an acid gas stream can be produced comprising predominantly CO₂ and H₂ S. The acid gas produced by this regeneration will be concentrated in H₂ S as compared with the H₂ S content in the gaseous feed to the invented process. For certain applications, if the acid gas stream from regeneration contains less than about 10-15 mol% H₂ S, a further selective H₂ S absorption stage can advantageously be used to further concentrate the H₂ S in the acid gas and to recover additional high purity CO₂ for other purposes.

The invention will be better understood and appreciated from the following detailed description of the drawings in which FIG. 3 represents schematically the first embodiment of the invention according to FIG. 1, utilizing a CO₂ sweetening absorber, a bulk CO₂ removal absorber, and a final hydrocarbon sweetening absorber, in sequence, to produce a residue gas having, for example, less than 4 ppm H₂ S and less than about 2 mol% carbon dioxide, as well as a sweet CO₂ product stream having less than about 100 ppm H₂ S and an acid gas stream enriched in H₂ S content.

Referring now to FIG. 3 in detail, a sour gaseous feed stream comprising 49 mol% carbon dioxide, 1 mol% hydrogen sulfide, and the remainder consisting of hydrocarbons such as methane, ethane, propane, and the like can be introduced by line 2 into the lower region of CO₂ sweetening absorber 4 and a lean alkanolamine solution, for example, MDEA or the like, can be introduced in an upper region via line 94 and flow control valve 96. The CO₂ sweetening absorber 4 can be operated under conditions effective for selective H₂ S removal as hereinabove described and the first gaseous product stream from which a substantial portion of H₂ S has been removed can be removed by line 6, compressor 8, and line 10, and introduced into the lower region of the bulk CO₂ removal absorber 12. When the sour feed gas is available at suitably high pressure, the compressor 8 will, of course, not be required.

In the bulk CO₂ removal absorber 12, the gaseous product stream provided by line 10 comprising predominantly hydrocarbons and carbon dioxide can be contacted with a semilean alkanolamine solution introduced at one or more points, for example, via lines 32 and 38, and carbon dioxide can be removed, for example, to less than about 5 to 10 mol% carbon dioxide. The second gaseous product stream from which the bulk of the carbon dioxide has been removed can then be passed overhead by vapor path 13 into the lower region of a final hydrocarbon sweetening absorber 14, which in the illustrated embodiment is combined in a single column with the bulk CO₂ removal absorber 12. Separate columns can, of course, also be utilized.

In the final hydrocarbon sweetening absorber 14, a lean alkanolamine solution can be introduced by line 110 into an upper portion, contacting and removing substantially all of the remaining hydrogen sulfide from the gaseous product stream introduced by vapor path 13 and producing a sweet gaseous product stream (residue gas stream) containing essentially all of the hydrocarbons and, for example, less than about 4 ppm hydrogen sulfide and less than about 2 mol% carbon dioxide, which can be removed by line 16.

The first rich alkanolamine solution can be removed from the CO₂ sweetening absorber 4 near the bottom thereof by line 5, passed in heat exchange relationship with lean amine from stripper column 72 in lean/rich exchanger 64, then by line 66, valve 68, and line 70 into an upper portion of stripper column 72. In stripper column 72, heat can be provided for generation of stripping vapor by removing liquid by line 120 to reboiler 122 and returning the heated liquid and vapor to the column. H₂ S and CO₂ desorbed from the rich alkanolamine solution in column 72 can be removed overhead by line 74, condenser 76, separator 78, and the acid gas overhead passed, for example, to a Claus sulfur recovery unit by line 80, or to an additional stage of selective H₂ S removal (not shown) for further concentrating the H₂ S in the feed for a Claus plant. Condensed aqueous liquid can be returned to the top region of column 72 from separator 78 by line 82, reflux pump 84, and line 86.

Lean, regenerated alkanolamine solution can be removed from the bottom of H₂ S stripper 72 by line 88, pump 89, cooled in lean/rich exchanger 64 in heat exchange relationship with the rich alkanolamine solution from CO₂ sweetening absorber 4, then passed by line 90, cooler 92, line 94, and flow control valve 96 to the upper portion of CO₂ sweetening absorber 4.

A rich alkanolamine solution can also be removed from final hydrocarbon sweetening absorber 14 near the bottom thereof, for example, by line 112, power recovery turbine 114, line 116, control valve 118, line 119 and combined with the rich alkanolamine solution from the CO₂ sweetening absorber in line 5, and thereafter treated as described above. Alternatively, when rich amine from the final hydrocarbon sweetening absorber is not trapped out, but is allowed to flow down into the bulk CO₂ removal section 12, a portion of the semilean amine from pump 28, (described in greater detail below) can be diverted via line 23 and valve 25 to line 70. Following regeneration, a portion of the lean amine in line 94 can be returned to the final hydrocarbon sweetening absorber 14, for example, by line 102, flow control valve 104, and line 110 to the upper region of the final hydrocarbon sweetening absorber 14.

It will be appreciated that although in the illustrated embodiment of FIG. 3, the rich alkanolamine solutions from the CO₂ sweetening absorber 4 and the final hydrocarbon sweetening absorber 14 are regenerated in a single H₂ S desorber 72, it is also possible and in accordance with the invention to use separate H₂ S desorbers for separate regeneration of each of these streams.

The rich alkanolamine solution from bulk CO₂ removal absorber 12 can be removed for regeneration, for example, by line 18, power recovery turbine 20, and provided by line 22 to CO₂ flash vessel 24. The heat necessary to sustain solution temperature can, if desired, be introduced into the flash vessel by a heater on the rich solution. Vapor can be removed from the flash vessel by line 40, cooled in condenser 42, and provided to separator 44. A sweet CO₂ stream having less than about 100 ppm H₂ S can be removed by line 46 from separator 44. The aqueous liquid from separator 44 can be returned to the flash vessel 24 by line 48. The semilean flashed amine solution can be removed from flash vessel 24 via line 26, pump 28 and line 30. A portion of the semilean amine solution in line 30 can be sent to cooler 36 by line 34, and can then be introduced by line 38 at the top of bulk CO₂ absorber 12.

FIG. 4 represents schematically the (second) embodiment of the invention according to FIG. 2 utilizing a bulk CO₂ removal absorber and a final hydrocarbon sweetening absorber in sequence to produce a residue gas having, for example, less than about 4 ppm H₂ S and less than about 2 mol percent CO₂ ; and further utilizes a CO₂ sweetening absorber on the sour CO₂ removed in the bulk CO₂ removal step to produce a sweet CO₂ product stream having less than about 100 ppm H₂ S and an acid gas stream enriched in H₂ S content. Also illustrated in FIG. 4 is the aspect of the invention according to which the sour CO₂ stream can be passed through an additional H₂ S selective absorption zone operated to produce an acid gas feed to a Claus Plant having greater than about 10-15 mol percent hydrogen sulfide.

Referring now to FIG. 4 in more detail, a sour gaseous feed stream comprising 90% CO₂ with a relatively low H₂ S content (0.2 mol% in the CO₂), and hydrocarbons can be introduced by line 150 into the bottom section 152 of vessel 153 operated for bulk CO₂ removal absorption. A semilean alkanolamine solution, such as, for example, MDEA, can be introduced by line 172 into the upper region of the bottom section 152 of vessel 153 under conditions as described above effective for absorption of at least a substantial portion of the CO₂ from the gaseous feedstream. The gaseous vapors from which a substantial portion of CO₂ and H₂ S have been removed then rise into top section 154 of vessel 153 operated as a final hydrocarbon sweetening absorber, and lean alkanolamine solution can be introduced in the upper region of section 154, for example, by line 290, further removing H₂ S and CO₂ from the rising vapors, thereby producing a residue gas stream which can be removed by line 156 having, for example, less than about 2 mol% carbon dioxide and less than about 4 ppm H₂ S.

Rich alkanolamine solution can be removed from the bottom of vessel 152, for example, by line 158 and power recovery turbine 159, and introduced into the upper stage of, for example, a two-stage flash CO₂ desorber having upper and lower stages 160A and 160B, respectively. In the first stage desorber 160A, the rich alkanolamine solution can be flashed at intermediate pressure, preferably with atomization by nozzles 162 and a substantial amount of CO₂ desorbed and removed by line 196. Liquid can be removed from the bottom of upper stage 160A by line 164 and introduced into the upper portion of lower pressure stage 160B again by flashing preferably with atomization by nozzles 166. Gases desorbed in the lower stage 160B can then be removed by line 165. Regenerated semilean alkanolamine can be removed from the bottom of CO₂ desorber 160B by line 168, and returned to bulk CO₂ removal absorber 152 by pump 170, and line 172.

A portion of the regenerated semilean solution removed from the base of CO₂ desorber 160B can be taken from line 172 by line 174, control valve 176, and line 178 and combined with rich amine in line 210 leaving the first stage selective H₂ S absorber 202, passed through heat exchanger 212 and introduced into stripper column 216. CO₂ and H₂ S in the combined amine stream can be desorbed in stripper column 216. The lean amine leaving the base of column 216 by line 242, pump 244, and line 246, after heat exchange in exchanger 212 can be passed by line 248 for cooling in air cooler 250. A portion of the cooled lean amine is drawn off via line 290 and returned to the hydrocarbon sweetening absorber 154. The balance is sent to the selective H₂ S removal absorbers via lines 252 and 256.

Desorbed acid gas removed from the low pressure desorber 160B by line 165 can be cooled in condenser 184 and provided by line 186 to separator 188. Aqueous condensate from the separator 188 can be returned to desorber 160 B by line 187. Acid gas removed from the separator 188 in line 190 can then be provided by compressor 192 and line 194 to be combined in line 198 with the CO₂ gaseous stream from the first stage desorber 160A in line 196.

The combined acid gas stream in line 198 from the two stage CO₂ desorber can be provided by line 200 to the lower region of a first CO₂ sweetening absorber 202. Lean alkanolamine solution can be introduced in an upper portion thereof, for example, by line 252, and H₂ S can be selectively removed as described above from the ascending gases. Ascending gas from which H₂ S has been removed can then be produced as a sweet CO₂ product stream removed by line 201. A recycle stream comprising CO₂ and H₂ S can be removed from the upper portion of the pre-Claus H₂ S selective absorber 204, also described below, by line 206 and recycled to the inlet of the CO₂ sweetening absorber 202 by lines 206 and 200.

Rich alkanolamine solution can be removed from the bottom of the CO₂ sweetening absorber 202, for example, by line 210, combined with semilean amine slipstream from line 178, and provided via lean/rich exchanger 212 to stripper column 216. In stripper 216, H₂ S and CO₂ are desorbed from the rich alkanolamine solution, for example, by steam stripping, with heat being introduced by removing liquid via line 240, heating in reboiler 238, and returning heated liquid and vapor by line 236. Lean alkanolamine solution from the bottom of stripper 216 can then be returned to the CO₂ sweetening absorber 202 and the pre-Claus H₂ S selective absorber 204 by line 242, pump 244, line 246, lean/rich exchanger 212, line 248, cooler 250, and lines 252 and 256, respectively. Desorbed gases can be removed from the upper portion of stripper column 216, for example, by line 260, condenser 262, and provided to separator 266. Condensed liquids can be returned to the desorber 216 by line 267.

Lean acid gas containing only about 0.2% H₂ S can be removed from the separator 266 by line 268 and enriched by pre-Claus H₂ S selective absorption. The acid gas can then be introduced by compressor 270 and line 208 into the lower portion of pre-Claus H₂ S selective absorber 204 having lean alkanolamine solution introduced in the upper region thereof by line 256. A rich alkanolamine solution can be removed from the bottom of selective absorber 204 by line 258 and provided to the pre-Claus H₂ S desorber 218 located in a column section above the stripper 216. In pre-Claus H₂ S desorber 218, H₂ S and CO₂ are desorbed from the rich alkanolamine solution, for example, by steam stripping. Gases removed from pre-Claus H₂ S desorber 218 can be provided by condenser 222 to separator 226. Condensate can be returned from separator 226 to the desorber by line 230. An enriched acid gas containing about 32 mol% hydrogen sulfide and suitable for Claus sulfur recovery can be removed by line 228. Alkanolamine solution can be removed from the bottom of pre-Claus H₂ S desorber 218 and provided by line 232 into the upper portion of CO₂ sweetening stripper 216 for further stripping as described above.

The invention will be further understood and appreciated from the following examples in which EXAMPLE 1 illustrates stream compositions and conditions according to the embodiment of FIG. 3 and EXAMPLE 2 illustrates stream compositions and conditions according to the embodiment of FIG. 4.

EXAMPLE I

TABLE 1
______________________________________
Stream Vapor Rate - mols/hr
Temp.   Press.
Amine
Number CO2
H2 S
HC   Total (°F.)
(psia)
(gpm)
______________________________________
2     931     19.0   950  1900  100    50   --
5     --      --     --   --    130    50   220
6     826     0.07   949  1775  114    46   --
13     208     0.01   948  1182  182   296   --
16      19     0.00   946  965   131   292   --
18     --      --     --   --    199   300   1500
30     --      --     --   --    180   316   1500
32     --      --     --   --    180   316   750
33     --      --     --   --    120   312   750
46     618     0.06    1   619   180    23   --
80     294     18.9    3   316   110    23
88     --      --     --   --    245    28   670
94     --      --     --   --    120   300   220
102    --      --     --   --    120   300   450
112    --      --     --   --    159   292   450
______________________________________
1 Columns 4, 12, 14, and 72 are modeled as having 16, 17, 20 and 20
trays, respectively; 50 wt % MDEA is used as absorption solution.

EXAMPLE II

TABLE 2
______________________________________
Stream Vapor Rate - mols/hr
Temp.   Press.
Amine
Number CO2
H2 S
HC   Total (°F.)
(psia)
(gpm)
______________________________________
150    8695   17      950  9662  120   310
156     10    3 ppm   860   870        300
158                              187   300
172                              160   330   11000
196    4340   9       50   4399  165   80
198    8685   17      90   8792  120   80
201    8651   0.7     90   8742  120   80
208     560   1        6    567  120   85
228     34    16.3    0.5   51   120   25
246                              252   130   3100
252                              120   90     300
256                              120   90    2800
290                              120   330    150
______________________________________
1 Columns 152, 154, 180, 202, 204, 216, and 218 are modeled as havin
30, 16, 20, 16, 16, 20, and 20 trays respectively; 35 wt % MDEA is used a
absorption solution.

It will be appreciated that there has been described a process for treating low quality gases which can achieve the following. First, the combination of CO₂ sweetening absorption and bulk CO₂ removal absorption according to the embodiment of FIG. 1 can produce a sweet CO₂ stream, containing less than, for example, 100 ppm H₂ S. Such a sweet CO₂ stream meets current environmental requirements for pipelining and is suitable for reinjection into CO₂ miscible flood produced reservoirs or for other use. Secondly, by utilizing both a CO₂ sweetening and a bulk CO₂ removal absorption step prior to the final hydrocarbon sweetening absorption step, the amount of H₂ S and CO₂ ultimately reaching the final hydrocarbon sweetening absorption zone is greatly reduced, allowing the H₂ S and CO₂ specification of the hydrocarbon residue gas to be easily met with relatively low amine circulation and low energy input. Thirdly, the CO₂ sweetening absorption step concentrates H₂ S in the acid gas removed to provide a suitable feed to a sulfur recovery plant.

Further, it will be appreciated that a process has been described which accomplishes the following. First, by utilizing a single amine solution to accomplish all of the several absorption steps described heretofore; it becomes possible to consolidate equipment with resultant simplification of the process and associated reductions in investment and operating costs. For example, the bulk CO₂ removal and hydrocarbon sweetening steps can be accomplished in a single absorption column. Further, the lean amine used for selective CO₂ sweetening and for hydrocarbon sweetening can be provided by stripping in a single column. The use of a single amine solution also reduces the cost of solution inventory and eliminates the problem of solution intermingling with savings in equipment required to segregate solutions.

While the invention has been described as required in terms of preferred embodiments and giving specific operating ranges and conditions, it is to be understood that the invention is not limited thereby, but by the claims appended hereto.

Claims

1. Process for the removal of hydrogen sulfide and carbon dioxide from a gaseous feedstream comprising hydrocarbons comprising:

introducing the gaseous feedstream into a CO₂ sweetening absorption zone and contacting the gaseous feedstream with a first lean amine solution stream under conditions selective for the removal of hydrogen sulfide relative to carbon dioxide and absorbing at least a major portion of the hydrogen sulfide from the gaseous feedstream producing a first gaseous product stream and a first rich amine stream containing absorbed hydrogen sulfide;

introducing the first gaseous product stream into a bulk CO₂ removal absorption zone and contacting the first gaseous product stream with a second lean (or semilean) amine solution stream under conditions effective for absorbing and removing a major portion of carbon dioxide from the first gaseous product stream and producing a second gaseous product stream and a second rich amine stream containing absorbed carbon dioxide; and

introducing the second gaseous product stream into a hydrocarbon sweetening absorption zone and contacting the second gaseous product stream with a third lean amine solution stream under conditions effective for removal of a major portion of all remaining carbon dioxide and hydrogen sulfide and producing a fourth gaseous product stream comprising hydrocarbons and a third rich amine stream, wherein

the first lean amine solution, the second lean (or semilean) amine solution, and the third lean amine solution each comprises an amine selected from the group consisting of tertiary amines and sterically hindered amines.

2. Process as in claim 1 wherein:

each of the first lean amine solution, the second lean (or semilean) amine solution, and the third lean amine solution, are substantially identical.

3. Process as in claim 2 further comprising:

introducing the first rich amine stream and the third rich amine stream into a first regeneration zone and removing absorbed carbon dioxide and hydrogen sulfide therefrom and producing an acid gas stream, the first lean amine solution stream and the third lean amine solution stream;

introducing the second rich amine stream into a second regeneration zone and removing absorbed carbon dioxide therefrom and producing a CO₂ product stream lean in hydrogen sulfide and the second lean (or semilean) amine stream.

4. Process as in claim 3 further comprising:

introducing the acid gas stream into a pre-Claus selective H₂ S removal zone and producing a first gaseous stream enriched in H₂ S and a second gaseous stream enriched in CO₂.

5. Process as in claim 4 comprising:

introducing the first gaseous stream enriched in H₂ S into a second pre-Claus selective H₂ S removal zone and producing a third gaseous stream enriched in H₂ S and a fourth gaseous stream enriched in CO₂.

6. Process as in claim 4 comprising:

introducing the second gaseous stream enriched in CO₂ to the feed to the CO₂ sweetening zone;

returning the fourth gaseous stream enriched in CO₂ to the first pre-Claus selective H₂ S removal zone;

7. Process for the removal of H₂ S and CO₂ from a gaseous feedstream comprising:

(a) introducing the gaseous feedstream into a bulk CO₂ removal absorption zone and contacting the gaseous feedstream with a first lean (or semilean) amine solution stream under conditions effective for absorbing and removing a major portion of carbon dioxide and a first portion of hydrogen sulfide from the gaseous feedstream and producing a first gaseous product stream and a first rich amine stream containing absorbed carbon dioxide and hydrogen sulfide;

(b) introducing the first gaseous product stream into a hydrocarbon sweetening absorption zone and contacting the first gaseous product stream with a second lean amine solution stream under conditions effective for removal of a major portion of the remaining hydrogen sulfide and producing a second gaseous product stream comprising predominantly hydrocarbons, and a second rich amine stream;

(c) removing absorbed carbon dioxide and hydrogen sulfide from the first rich amine stream and the second rich amine stream and producing a first acid gas stream containing such removed carbon dioxide and hydrogen sulfide;

(d) introducing the first acid gas stream into a CO₂ sweetening absorption zone and contacting the acid gas stream with a third lean amine solution stream under conditions selective for the removal of hydrogen sulfide relative to carbon dioxide and absorbing at least a major portion of the hydrogen sulfide from the acid gas stream producing a third gaseous product stream comprising predominately carbon dioxide and a third rich amine stream containing absorbed hydrogen sulfide; and

(e) removing absorbed hydrogen sulfide from the third rich amine stream and producing a second acid gas stream containing such removed hydrogen sulfide, and the third lean amine stream, wherein

(f) the first lean (or semilean) amine solution, the second lean amine solution, and the third lean amine solution each comprises an amine selected from the group consisting of tertiary amines and sterically hindered amines effective for selective removal of hydrogen sulfide relative to carbon dioxide.

8. Process as in claim 7 wherein:

the first lean (or semilean) amine solution, the second lean amine solution and the third lean amine solution are substantially identical.

9. Process as in claim 8 wherein step (c) of claim 7 comprises:

introducing the first rich amine stream and the second rich amine stream into a first regeneration zone and removing absorbed carbon dioxide and hydrogen sulfide therefrom and producing a first acid gas stream, and the first lean (or semilean) amine solution stream,

introducing the third rich amine stream and a portion of the first lean (or semilean) amine stream, essentially equal in volume to the second lean amine stream, into a second regeneration zone, producing a second acid gas stream enriched in hydrogen sulfide, the second lean amine stream, and the third lean amine stream.

10. Process as in claim 7 further comprising:

introducing the second acid gas stream into a pre-Claus selective H₂ S removal zone and producing a third acid gas stream enriched in H₂ S and a gaseous stream comprising primarily CO₂.

11. Process as in claim 10 further comprising:

combining the gaseous stream comprising primarily CO₂ with the first acid gas stream, and contacting the thus combined stream with the third lean amine solution under conditions selective for the removal of hydrogen sulfide relative to carbon dioxide.